Industrial Training & Project Review

Presentation
By
SAURABH CHAVAN
ISHWAR SHENOY
B.E. (Printing & Packaging Technology)
On
Wastage Analysis and Scope Of Wastage Reduction In Sheetfed
Offset Printing

Department of Printing & Packaging Technology

Under the Guidance of Industrial Training Organization

Prof. GAURAV FASATE AJANTA PRINT ARTS

1
 Industrial Training
Brief about the Organization
Vision
“To become the most preferable vendor for all needs of packaging within 2020
by providing trendsetting value added packaging solution.”
Mission
“To provide better service, better quality products and to satisfy the needs of
the customer.”
Brief background with year of inception and company locations:
Ajanta Print Arts was incorporated in 1952 by Late Shri Jaigopal Khanna as a
commercial art studio. The decision to move into print production was taken
during 1955 and consistent growth has followed since.
Corp Office: Airmail Pen House, 4th Floor, Tejapal Scheme Road No.5, Vile Parle
East, Mumbai 57, India.
Factory: Plot B-24,TTC Industrial.Area, Old Pipline Road. Behind Siemens Ltd.
MIDC, Airoli, Navi Mumbai - 400708.

2
 Industrial Training

Products / Service Profile

● Mono Cartons from different variety of board.
● Display Cartons with different kind of windows & Variety of dispensers.
● Cartons with different kind of PP & Met-pet printing.
● In-mould Labels catering to food, paint, petroleum & oil industry.
Customers / Clients
● Ferrero
● kellogg’s
● Amul
● Mother Dairy and more….
Certifications / Awards -
1. BRC/IoP Certification (British Retail Consortium / Institute of Packaging)
2. SEDEX Certification (Supplier Ethical Data Exchange)
3. FSC Certification ( Forest Stewardship Council )

3
 Industrial Training

Challenges faced by company:

1. Printing on In Mould Labels and its waste minimization.

2. Print Waste minimization during make ready process.
3. To maintain proper ink density on non-absorbent substrate.

Information about machines-

PRE-PRESS UNIT:
1. Kornsgberg XE 10 – Sample Maker
2. Kodak Computer to Plate
3. Epson Color Proofer

4
PRINTING UNIT :

● KBA RAPIDA 106

(Specifications- 7 color + Coater + UV + Conventional ) (UV ,Aqueous ,
Varnish Coatings)
● KBA RAPIDA 72
(Specifications- 5 color + IR Lamp)
● KBA RAPIDA 72V
(Specifications- 6 color + Coater )
● KBA RAPIDA 105
(Specifications- 6 Color + Conventional + Coater i.e Aquous , Varinish)
● KBA RAPIDA 104
(Specifications- 2 Color + UV + Conventional)

5
POST PRESS UNIT
● AUTOMATIC PUNCHING -
1) BOBST SP-102SE (Max Sheet Size:28.3″ x 40.15″ ) 7500 Sheets/hour
2) BOBST NOVA CUT 106E (Max. Sheet Size: 29.125″ x 41.75″)
8000 Sheets/hour
3) BOBST SP 102 BMA (Max. Sheet Size:41” x 28″)7500 Sheets/hour

● OFFLINE COATER -
1) ULTRA COAT 1040 (Max Sheet Size 40” x 28”)

● LAMINATION -
1) STEINEMANN

● AUTOMATIC PASTING-
1) BOBST Media-68 SE (Open Blank Width Min 106mm Max 680mm
Open Blank Length Min 60mm Max 600mm)

6
 Industrial Training
Lessons learnt and Work done in the company
● Operations carried out in the pre press department.
● Production make ready changes from one substrate to another.
● Learned what is IML and how the printing is done.
● Maintaining batch manufacturing records .
● Tests done on the printed sheets such as Scotch test ASTM D3359-02 ,
Rub Resistance MEK test ASTM D4752,Abrasion Resistance Test ASTM
D5264 .

7
 Project
“Waste Analysis And Scope Of Wastage Reduction In
Sheetfed Offset Printing”
Abstract:
Sheet-fed offset is mostly used for printing of short run jobs such as posters,
cartons, Brochures and leaflet printing. In sheet-fed offset, "the printing is
carried out on single sheets of paper as they are fed to the press one at a
time" different types of substrates can be used in sheet-fed offset printing
for production like Coated, Un-coated, Duplex, Virgin Board, Board with
METPET, Blister Card , In Mould Label & Polypropylene (PP). During project
work , jobs consuming different types of printing substrates were considered
The purpose of this work is to map the current substrate waste scenario in
the Ajanta Print Arts, investigate its causes and suggest an approach for how
substrate waste can be reduced in the company.
Keywords: Absorbent and Non Absorbent Substrates , Sheet Fed Offset
Process, Printing Substrate, Waste.

8
Need -
● The need of this report is to give a detailed view of the current waste situation
during printing at Ajanta Print Arts, investigate its causes and suggest an
approach for how waste can be reduced in the company.

Scope -
● This project concentrates on analyzing the defects and finding solutions to those
defects in “Ajanta Print Arts”, Airoli.

Objective -
● To study the actual printing process.
● To evaluate various defects in sheetfed offset printing.
● To analyse the best practices used for reduction in wastage of carton and label
manufacturing process.

9
 Project Methodology / Action Plan
Action Status Start Date End Date Remarks

Study about different properties of raw

Completed 08/02/2020 09/02/2020
materials

Study and observe printing done on

Completed 10/02/2020 23/02/2020
various substrate

Finding the problem statement Completed 11/02/2020 23/02/2020

Monitor actual and observed wastage (

Completed 24/02/2020 19/03/2020
In Sheets)

Examine Various parameters influencing

Completed 24/02/2020 19/03/2020
the wastage

Define and Study the parameters

Completed 11/04/2020 21/04/2020
influencing the wastage

Suggest remedies Completed 22/04/2020 28/04/2020

Report Completed 28/04/2020 10/5/2020

10
Process Flowchart Problem Area in the organisation

11
 Project
Review Of Literature 1
● Sangita Yadav, Bhupender Yadav & Ravinder Singh et al.reviewed the “Sheet
Fed offset presses for optimum consumption of printing substrates”.
● Aim- To reduce the wastage of the printing substrates used in different sheet
offset presses.
● Methodology - Jobs consuming moderate amounts of printing substrate were
selected and the study was conducted on each selected job.
● Response - Checklist had been incorporated in the printing section on sheet-fed
offset machines. It was in the tabular form to check the different factors like
Fountain Solution and Ink problem , Feeder /Printing /Delivery Problem on a
particular machine on daily printing before handling all jobs.
● Observation - The checkpoints helped to reduce the wastage of printing
substrates.
● Conclusion -There was significant reduction in wastage when the suggestions
were implemented in correct manner and also controlling the factors that
influence the wastage.

12
 Project
Review Of Literature 2
● Arohit Goyat, Nishan Singh, Rakesh Kumar et al.reviewed “The machine, man,
method & material model for wastage reduction”.
● Aim - Optimization and wastage reduction of folding box boards in the
packaging industry during the Manufacturing, Prepress, Press and Post Press
Section.
● This was the case study of ITC Limited.
● Factors - Man, Machine, Method, Material, were considered, because of
which wastage takes place.
● Conclusion - There were several factors due to which the Paperboard wastage
occurred during printing in the press room such as printing defects,
paperboard and ink problems, machine problems, as well as external factors
such as atmospheric humidity, and room temperature.
● Response - Implementation of action plans as an response to the factors
observed, ensured reduction in wastage from 7.18 % in February 2012 to 3.84
% in March 2012.

13
 Project
Review Of Literature 3
● Arohit Goyat, Sangita Yadav & Bakshinder Kaur et al. reviewed “Perspective of
Total Quality Management and wastage reduction in corrugation printing ” .
● Objective - To improve the quality of corrugated boxes by Implementing TQM
Process and to reduce the wastage of Kraft paper & corrugated boards by
using different techniques in “Asian Group of Industries, Baddi”.
● Methodology -
1) Some jobs of the “Asian Group of Industries, Baddi ” were selected in
which Paper & Board wastage was more & each selected job was analyzed and
examined.
2) Data Related to Quality management & Wastage Reduction was collected
during the study.
● Response - Checklist was developed according to the job and the machine
availability and the checkpoints were checked before the initiation of each
task which would result in reduction in wastage while printing of day to day
jobs.
● Conclusion - After the suggestions were implemented for there was significant
reduction in the wastage .

14
 Project
Wastage comparison of substrate during printing

Board Paper Plastic (PP) Board with MET PET Plastic (In mould labels)

Wastage 2.09% 1.82% 3.46% 3.96% 4.69%

(Cumulative average of substrate waste from 24th Feb 2020 till 19th March 2020)

Note - Absorbent Surface is from Line 4 and Non Absorbent Surface is from Line 1
Machines 15
 Project
Results and discussions
There may be several reasons because of which waste is generated during the
printing process .
● Material
● Machine
● Method

Remedies for defects observed

1. Material Problems -
Causes - Damage Sheets , Wavy Sheets .
Solution -Check the damage sheets and seperate it .Cover the pile board
properly, Jogging of the sheets .

16
 Project
2. Machine Problems -

● Feeding Unit -
Cause - Static Charge problems occurs In non absorbent substrates such
as IML , PP and PET Substrates . Static problems cause multiple sheets
getting picked up by the sucker because of the improper setting of the
double sheet detector .
Solution - Proper cleaning of the antistatic equipment . Maintaining the
temperature of the printing area . Checking the Suction capacity of the
Suckers .

● Dampening and Inking Unit -

Causes - Ink Drying too fast . Ink Drying too Slow .
Solution - Ink and Water balance is one of the most important factors
which need to be considered while printing .Apart from these
Conductivity should be 800 to 1500 µS/cm and pH of the fountain
solution should be between 4-4.5 . Dampening solution should have a
water hardness of 8 ° dH to 12 ° dH and temperature ranges between
10 °C to 15 °C.
17
 Project
● Delivery Unit -
Causes - Overshoot problem, dust problem .
Chips of IML coming out due to loosening of the bolts of the gripper .
Solution - Check all the bolts and change the Damaged bolts .

3. Method Problems -
● Shade Variation -
Problems Remedies

Substrate variation Discuss with the Inventory supervisor of

the substrate to change the stock
Special/ Process Colors does not Match Consult Ink Manufacturer , Maintain
SOPs.
Speed is Increased Reduce the machine speed

18
 Project
● Misregistration -

Problems Remedies
Alignment of plate, blanket , substrate Check the alignment before full length
not proper production
Blanket and its packing not proper Replace Blanket or its packing
Press sheets not trimmed properly Trim the sheets

● Scumming -

Problems Remedies

Printing pressure not uniform Adjust Printing Pressure

High Ink Viscosity Decrease ink Viscosity
Plate not processed properly or exposed Desensitize or Remake the plate , Adjust
to light . plate making process

(Note - The value of printing pressure , Viscosity is already determined by the Machine
depending upon the inputs given about the substrate dimension , gsm and etc )
19
 Project
● Set-off -

Problems Remedies
Substrate Sticks on the the on the other Increase the Powder application
substrate
Ink dries too slowly Check the drying and type of UV lights
used.

● Mottle -

Problems Remedies

Printing pressure not uniform Adjust Printing Pressure

Improper ink/water balance Adjust to proper ink / water balance
Worn out blanket Replace blanket .

20
 Project
Wastage Analysis

● Chart depicts a control chart without the Job No 4 which is an outlier .

● Mis-registration was one of the defects majorly observed and detected in job 3
and 7
● The Static Charge problem was majorly found in Job 7 , Job 8 and Job 9 .

21
 Project
Wastage Analysis

● Chart depicts a control chart without the Job No 10 which is an outlier .

● Mottle was one of the main defects that occured in MET-PET sheets . It was
detected in Job No 1,2,3,4,5,10, 12 ,13 ,14 and 16 .
● It was found that Printing pressure was not uniform and hence the pressure was
reduced and the machine speed was also reduced which caused a decrease in
Mottle defect.
22
 Project
Wastage Analysis

● Chart depicts a control chart without the Job No 3 which is an outlier .

● Scum was majorly observed Job 3 , Job 4 and Job 5 which consisted of yellow
color Inks .
● Shade Variation was most common in Job 1 and 2 which caused wastage .
● Apart from these printing problems there were also Static Problems which were
significantly reduced by using Anti Static Brushes and Blowers which brought
down the Static Charge values.
23
 Project
During training time ,Following Checklist was Proposed to achieve better results in
waste minimization.
1. Clean all the units of the machine properly like - feeding units, delivery unit,
inking unit, dampening unit and inking unit.
2. Clean the Dampening chillers .
3. Check the blanket and change the packing .
4. Clean and adjust the pH, conductivity and IPA value.
5. Clean the Coater Unit.
6. Check and clean all the air conditioners.
7. Setting of dampening and inking rollers .
8. Close all the doors of the production room.
9. Check the feeding unit before starting the job and proper setting of air blowers,
suckers, double sheet detector and antistatic equipment.
10. Replace new sheets with old sheets or sheets which have been used in previous
jobs, for color matching as well as for make ready purposes.

24
 Project
Conclusion
There are various reasons because of which wastage occurs during printing such
as Substrate Problems , Printing defects and Machine Defects. Apart from this
there are some external factors such as room temp and humidity which play an
important role in reducing wastage.Controlling these parameters and
maintaining standard SOPs will ensure a reduction in wastage.

Limitation - Before drawing any conclusion based on this presentation it may be

noted that it was prepared in a short period of time and due to this the checklist
has not been incorporated in the company.But still the presentation may be
useful for Analyzing wastage in the Printing and Packaging Industry .

25
 Project
References
1. Sangita Yadav ,Bhupender Yadav & Ravinder Singh ,2018 , An overview of sheet fed offset
presses for optimum consumption of printing substrates . International Journal of Engineering
Sciences and Research Technology (IJESRT) , [online] .
Available at -
https://www.academia.edu/35850880AN_OVERVIEW_OF_SHEET_FED_OFFSET_PRESSES_FOR_O
PTIMUM_CONSUMPTION_OF_PRINTING_SUBSTRATE?auto=download
2. Arohit Goyat, Nishan Singh ,Rakesh Kumar,2016 . The machine, man, method & material model
for wastage reduction. International Journal of Engineering Sciences and Research Technology
(IJESRT) , [online].
Available at http://www.ijtre.com/images/scripts/2016031223.pdf
3. Arohit Goyat, Sangita Yadav & Bakshinder Kaur ,2018 .Perspective of Total Quality Management
and wastage reduction in corrugation printing . International Journal of Engineering Sciences and
Research Technology (IJESRT) , [online]
Available at - http://www.ijesrt.com/issues%20pdf%20file/Archive-2018/March-2018/56.pdf
4. shodhganga.inflibnet.ac.in/bitstream/10603/153276/15/10_chapter%202.pdf
5. http://printwiki.org/Ink
6. https://en.wikipedia.org/wiki/Offset_printing#Sheet-fed_offset
7. www.monochrom.gr/UserFiles/SFTSG.pdf
( Note -These are the references only of the presentation)
26